KR20230000468A - Stators for Electric Machines - Google Patents

Abstract

Provided is a stator that interacts with magnets carried by a rotor of an electrical machine. The stator comprises: an active region arranged to be aligned with the magnets carried by the rotor; a first passive region and a second passive region separated by the active region; and a slotless phase winding including a plurality of conductive elements. Each of the conductive elements includes a conductor provided in an insulating housing, and the slotless phase winding is arranged in a serpentine structure. The structure includes: a first active segment in which the conductive element extends across the active region from the first passive region to the second passive region; a second active segment in which the conductive element extends across the active region from the second passive region to the first passive region; and a passive segment for coupling the first active segment to the second active segment. The passive segment includes turns provided in the second passive region, and at least one of the conductive elements is twisted in the second passive region.

Description

Stators for Electric Machines

The present disclosure relates to the field of stators for electrical machines.

An electrical machine, such as a motor, is configured to convert electrical energy into mechanical energy. Electrical machines generally include a stator and a rotor. The stator surrounds the rotor and includes one or more windings. A rotor has one or more magnets and is coupled to a shaft. By applying current through the windings of the stator, the generated magnetic field interacts with the magnets in the rotor to drive rotation of the rotor and shaft.

Small but powerful electric motors today are used in a variety of mobile applications such as lawn mowers and battery or hybrid powered vehicles. In the past, most of these machines were powered by combustion engines.

Aspects of the disclosure are described in the independent claims, and optional features are described in the dependent claims. Aspects of the present disclosure may be provided in conjunction with each other, and features of one aspect may be applied to other aspects.

In one aspect, a stator is provided for interacting with a magnet carried by a rotor of an electrical machine. The stator includes an active area arranged to align with the magnets carried by the rotor; a first inactive region and a second inactive region separated by an active region; and a slotless phase winding comprising a plurality of conductive elements. Each conductive element includes a conductor provided in an insulating housing. The slotless phase winding is arranged in a serpentine structure comprising: a first active segment in which the conductive element extends across the active area from a first non-active area to a second non-active area; a second active segment wherein the conductive element extends across the active area from the second inactive area to the first inactive area; and an inactive segment coupling the first active segment to the second active segment, the inactive segment including a turn provided in the second inactive area, and wherein at least one of the conductive elements is twisted in the second inactive area. (twisted).

Embodiments may provide a stator with increased efficiency. In particular, the stator may reduce circulating voltage and/or eddy current losses generated during operation of the stator. The stator can provide an efficient wide gap stator. An insulating housing for each conductive element can reduce eddy current losses associated with each conductor during operation of the stator. Twisting of at least one of the conductive elements can change the separation distance between each conductor and the magnet carried by the rotor (eg, such that the separation distance changes relative to the active area of the stator). This may reduce the total voltage integral associated with the stator, since individual sub-integrals for smaller sections of windings may deviate (e.g. adjacent sections of windings). ), since these deviations are averaged across the stator. Consequently, this will reduce the overall total voltage integral across the stator, increasing the efficiency of the stator's operation. For example, the placement of the conductive elements and one or more inactive region twists may be selected to minimize voltage integration across the stator as a whole (eg, across one or all of the phase windings of the stator).

Electrical machines may include slotless direct current machines. Electrical machines may be arranged to operate as motors and/or generators. Thus, the magnets of the stator and rotor interact to (i) transfer electrical energy from the stator (in the form of currents/voltages applied to the stator windings) to kinetic energy (in the form of rotation) of the rotor, and/or (ii) transfer kinetic energy (in the form of rotation) from the rotor to electrical energy (in the form of generated current) in the stator.

In the case of a motor, the stator is configured to selectively apply current to the phase windings to create a corresponding magnetic field for interacting with the magnets of the rotor. This magnetic field provides the resulting force to the permanent magnets in the rotor. Force applied to the magnets of the rotor will drive the magnets (and therefore the rotor itself) to move against the stator windings. In particular, the rotor may be configured to rotate about an axis of rotation, and selective application of a current to the phase windings may cause the rotor to rotate about an axis of rotation. In other words, in the case of a motor, the stator is configured to selectively energize the phase windings to drive rotation of the rotor. For example, a stator is for interacting with a magnet carried by a rotor of an electric motor, and the stator is configured to apply current to the slotless phase windings to drive rotation of the rotor of the electric motor.

In the case of a generator, energy will be transferred from an external source to the rotor, causing the rotor to rotate about an axis of rotation. In doing so, rotation of the permanent magnets relative to the phase windings of the stator will induce current in the phase windings. This generated current can be used as electrical energy (eg, for storage or for use in powering an electrical circuit). In other words, the stator is configured to selectively utilize electrical energy generated by rotation of the permanent magnets of the rotor relative to the phase windings of the stator. For example, the stator is for interacting with magnets carried by the rotor of the generator, and the stator is configured to utilize energy from current produced in the slotless phase windings in response to rotation of the magnets of the rotor of the generator. .

A stator is arranged to operate in combination with the rotor. In particular, the stator may be configured such that when used in combination with a rotor the phase windings of the stator are aligned with the permanent magnets on the rotor. Permanent magnets may occupy the active area of the rotor. That is, the magnets of the rotor may be provided on the surface of the rotor forming the active area. The magnetic field from permanent magnets will be strongest in the volume adjacent to this active region. In particular, the magnetic field will be strongest in the region aligned with the active area of the rotor, and this field will decrease in strength with distance from the permanent magnet. The stator may be controlled to operate based on signals received from sensors in the electric machine. For example, a sensor for detecting a rotational position of the rotor may be provided, and an operation of the stator may be controlled based on the detected rotational position.

The stator may be arranged in alignment with the rotor such that the active area of the rotor (where the permanent magnets are) is aligned with the active area of the stator's phase windings. This may include an active area of the stator horizontally or vertically offset from the active area of the rotor. However, the active area of the stator may be offset only vertically or only offset horizontally, for example to maximize alignment between the active area of the stator and the active area of the rotor. The inactive regions of the stator may include regions that are not aligned with the magnets of the rotor. The inactive area may include an area located beyond the end of the active area of the rotor.

In other words, the active area of the stator may include the area of the stator where the magnetic field generated by the permanent magnets of the rotor is highest. For example, an active area of a stator may include an area of the stator that is aligned with the rotor when the rotor is in position relative to the stator of the electric machine. The inactive regions of the stator may include regions of the stator where the magnetic field from the permanent magnets is lower (eg, regions not aligned with the magnets).

The stator may be configured for one of two different types of gap between the stator and the rotor of an electrical machine used in combination with the stator. That is, the stator/rotor may have a radial gap or an axial gap.

As a first example, the stator may be arranged to provide a radial air gap between the stator and the rotor. In this case, the stator and rotor may be coaxial with each other about the axis of rotation of the rotor, and the two are radially offset from each other about the axis of rotation. For example, the stator may be arranged radially outward of the rotor. The stator may enclose a volume in which the rotor may be provided. Thus, the stator may form a hollow cylinder as well as an air gap between the stator and the rotor. The rotor may be cylindrical and may be provided within a hollow cylinder of the stator. A permanent magnet may be provided on the surface of the cylinder of the rotor. The active area of the rotor may be a cylindrical surface provided with magnets. The active area of the stator can be configured to correspond to the active area of the rotor, such that the active area of the stator also includes a cylindrical surface. This cylindrical surface (active area) of the stator may be arranged in alignment with the cylindrical surface (active area) of the rotor such that the active area of the rotor fits within the active area of the stator. Both of the longitudinal ends of the active area of the rotor may fit within the longitudinal extent of the active area of the stator (eg, the longitudinal ends of the active area of the rotor and the active area of the stator may be the same). The inactive area of the stator may include an area that is axially offset from the active area of the stator and/or the magnet (active area) of the rotor. For example, the first inactive area can be axially offset from the second inactive area. The active area of the stator may be in the axial area between the first and second inactive areas (as may be the permanent magnets of the rotor).

In the case of a radial air gap stator, the conducting elements of the phase windings may run parallel to the axis of rotation of the rotor in the active area of the stator. That is, in the active area, the active segment extends in the axial direction. By rotating in each inactive area, the conductive element can extend axially rearward across the active area of the stator towards the other inactive area. Rotation of each inactive area may rotate 180 degrees to reverse the axial direction of the conductive element. The conductive element can be twisted when extended around a turn.

As a second example, the stator may be arranged to provide an axial air gap between the stator and the rotor. In this case, an axial offset may be provided between the stator and the rotor. The stator and rotor may be coaxial with each other. Both the stator and the rotor may be circular in cross section (cross section perpendicular to the axial direction). The permanent magnets may be arranged annularly on the surface of the rotor. The surface of the rotor may have a central circular area that is not provided with permanent magnets. Radially outside of the central circular region may be an annular region containing permanent magnets. Radially outside of the annular area containing permanent magnets may be another area without any permanent magnets. The annular area of the surface of the rotor may provide the active area of the rotor (eg, the area where the permanent magnets are located). The annular active area of the rotor can be aligned with the active area of the stator. In other words, the active area of the stator can include an annular area that can be aligned with the active area of the rotor, such that the two can be axially offset, but the active area of the rotor is radially inward of the active area of the stator. or does not extend outward. The inactive regions of the stator may be regions radially inward and radially outward of the active regions of the stator (eg, regions not axially aligned with the permanent magnets of the rotor).

In the case of an axial air gap stator, the conductive elements of the phase windings may extend radially across the active area of the stator. In other words, the active segments of the slotless phase winding can extend in a radial direction orthogonal to the axis of rotation of the rotor. That is, in the active area of the stator, the conductive element will extend radially towards and away from the center of the stator surface. In the inactive area, the element can rotate so that it can again extend across the active area in a radial direction toward another inactive area.

The stator may include a flux ring. The phase windings may be coupled to a flux ring. For example, the phase windings can be mounted directly on the flux ring and/or the phase windings are mounted on an intervening layer (eg a polymer layer) to secure the windings to the flux ring. It can be. In the case of a radial air gap stator, the flux ring may include a hollow cylinder arranged to enclose the phase windings (and permanent magnets on the rotor). For an axial air gap stator, the flux ring may include a disk arranged to be axially offset from the active area of the stator (and permanent magnets on the rotor) and to span a radial extent of the windings. A flux ring may be located opposite the phase windings to the permanent magnets on the rotor. The conductive element may be separated from the permanent magnet by an air gap (eg nothing else). The stator may also include a housing in which the components of the stator are provided.

Each conductive element includes a conductor provided within an insulating housing. The insulating housing may completely enclose the conductor along its length. The insulating housing may insulate each conductor from adjacent conductors of the phase winding. The phase winding includes a plurality of conductive elements. Conductive elements of the phase winding may be packaged in bundles. A bundle may include a plurality of conductive elements stacked together. Conductive elements may be stacked into bundles according to selected shapes (eg, such that the bundles provide a selected cross-sectional shape). The selected shape may be symmetric about at least one axis. The selected shape may be symmetric about a plurality of axes. For example, the selected shape may allow the bundle to be rotated in such a way that its cross-sectional shape is maintained, but the placement of the conductive elements within the shape has been changed. For example, the cross-sectional shape of a bundle can have orthogonal sides (eg, square or rectangular) or the sides can be non-orthogonal, while still retaining its shape (eg, according to all regular polygons) and conducting elements. The different configurations of can allow rotation of the shape. For example, the conductive elements may be arranged in a hexagonal structure.

The shape of each conductive element in the cross section may be uniform. The insulating housing may be of equal thickness around the conductor. The cross-sectional shape of each conductor may (or may not) be selected to correspond to the cross-sectional shape of the bundle. For example, the conductor may have a hexagonal, circular, or rectangular cross-sectional shape. A conductor may be symmetric about at least one axis. The conductor may have a cross-sectional shape such that it can be rotated about at least one angle (not a multiple of 360 degrees) to retain its shape but change its relative orientation. Each conductive element may have a thickness (eg diameter) between 10 microns and 2000 microns, such as between 100 microns and 700 microns, such as between 160 microns and 400 microns.

The conductors of each conductive element may be parallel to the conductors of other conductive elements in the same bundle. For example, in the active area of the stator, the conductors of the bundle may extend across the active area parallel to each other. The conductor may not be compressed in the active area. The conductor may not be twisted in the active area. The conductors can be arranged to increase the conduction density within the region of the bundle of active areas, for example. The conductors may be stacked parallel to each other (geometrically rather than electrically parallel). The phase windings may include terminal wires. The phase windings may be coupled to a commutator, such as a multi-phase commutator (eg, when operating as a motor). The phase windings may be coupled to a power source for supplying current to the windings. A voltage sub-integral may be generated separately for each conductive element (eg, due to the electrically insulated element).

The serpentine structure may include a plurality of active segments and a plurality of inactive segments. The serpentine structures may be arranged in series such that each active segment leads to an inactive segment and then from the inactive segment to the next active segment. For example, in each active segment, the conductive element may extend straight across the active area from one inactive area to another. Each inactive segment can join two active segments together through a turn, whereby the conductive element can extend back in a straight line across the active area of the stator from one inactive area to the other. there is. Each active segment of a phase winding may be separated from an adjacent active segment by a threshold distance (eg, such that active segments from other windings may be provided in a separation region). Each conducting element of a phase winding (eg, in the same bundle) may follow the same meandering path to the stator.

Each active segment may include a region in which a conductive element is aligned with a permanent magnet of the rotor (eg, in a region where the magnetic field strength is relatively high). Each inactive segment may include a region that is out of alignment with the permanent magnets of the rotor, such as where the conductive elements are axially or radially offset from the magnet (eg, in regions where the magnetic field strength is relatively low). The conductive elements of the active segment are arranged to interact with the magnets of the rotor. For example, in the case of a radial gap, the conductive element of each active segment extends axially (parallel to the axis of rotation of the rotor) between the inactive regions. Thus, the active segments are a series of straight axial segments disposed on the surface of the cylinder aligned with the magnets of the rotor. For example, in the case of an axial gap, the conductive element of each active segment extends radially (perpendicular to the axis of rotation of the rotor) between the inactive regions. Thus, the active segments are a series of straight radial segments disposed on an annular region aligned with the magnets of the rotor.

Each conductive element can exit the active area into an inactive area, after which the conductive element is rotated to re-enter the active area from the inactive area. Current flowing along the conductor of each conductive element will move from an active area to an inactive area, where the element is rotated so that the current flows back into the inactive area. Each rotation may provide a continuity path whereby the conductive element bends back to the active area. Rotation may or may not include a twist. If no twist is provided, rotation can bend the conductive element around and return from the inactive area to the active area with the same configuration that entered the inactive area. If there is a twist in the inactive area, the conductive element will bend from the inactive area back to the active area, but in a different configuration than it entered into the inactive area. Rotation can involve bending in the same plane or bending can involve components out of that plane. For example, the first active segment and the inactive segment can be provided in the same plane, or the inactive segment can extend out of that plane as it rotates in the inactive area. Rotation includes bending of the conductive element to move the active area from a first direction (a direction across the active area from a first inactive area to a second inactive area) to a second direction (from a second inactive area to a first inactive area). direction that crosses it again).

The plurality of conductive elements can be substantially parallel to each other in the first and/or second active segments. For example, in each active segment of a phase winding, the conductive elements in that bundle will run parallel to each other in the active region. The conductive elements may not run parallel to each other in the inactive area (eg, when twisted or rotated). The conductive element of the first active segment may be substantially parallel to the conductive element of the second active segment. For example, in the case of a radial gap stator, each active segment may be parallel to each other and to the axis of rotation of the rotor. In the case of an axial gap stator, each active segment may not be parallel to an adjacent active segment, but the separation distance between adjacent active segments at the boundary between the active region and the first inactive region is equal to the boundary between the active region and the second inactive region. may correspond to the separation distance between adjacent active segments in For example, in an axial gap stator, two adjacent active segments may extend along a line such that the two lines intersect at the center of the stator (if so extended). The conductive element may extend untwisted in a straight line across the active area.

At least one of the conductive elements is twisted in the inactive area. For example, torsion may occur when at least one conductive element extends around a rotation. Twisting may be for a single conductive element within the phase winding, or may be for a plurality of conductive elements of the phase winding as a whole (eg, a bundle of conductive elements forming the phase winding). For example, torsion refers to rotation about a longitudinal axis, such as rotation of an individual conductive element about a longitudinal axis of that conductive element, and/or rotation of a bundle of conductive elements about a longitudinal axis of a bundle of corresponding conductive elements. can include The longitudinal axis of an individual conductive element may include a central axis extending along the length of the element as it follows its way along the serpentine structure. The longitudinal axis of the bundle of conductive elements may include a central axis of the bundle extending along the length of the bundle along the serpentine structure.

The conductive element may be twisted in that it has been rotated about a longitudinal axis. A conductive element can transition from a first active segment to an inactive segment having a specific orientation, and the conductive element can transition from an inactive segment to a second active segment having a different orientation. For example, the orientation of the conductive elements can be changed such that, for example, the conductive elements are presented in different orientations in adjacent active segments. For example, the conductive element of the first active segment may be in a different rotational position relative to the conductive element of the second active segment.

A conductive element may be twisted in that its position and/or orientation relative to other conductive elements of the phase winding is changed. For example, the placement of conductive elements within the plurality of conductive elements of the phase winding can be varied between the first and second active segments. For example, for any one conducting element of a phase winding, the separation distance to the magnets of the rotor is meandering (eg, so that the conducting element is in some active regions closer to the rotor magnets than in other active segments). It can change as it is extended along the serpentine structure.

In the case of phase windings, a plurality of conductive elements may be packaged in a bundle. The bundle may have a shape selected in cross section. The cross-sectional shape selected for the bundle may be the same in adjacent active segments (eg the selected cross-sectional shape may remain constant for all active segments of the stator). However, the placement of conductive elements within a given bundle may be varied between different active segments, for example such that conductive elements in subsequent active segments have different positional configurations. For example, when viewing a bundle in a cross-section of a first active segment compared to a second active segment, one or more conductive elements may be individually rotated and/or the bundle itself may be rotated as a whole. Consequently, the configuration of the plurality of conductive elements of the phase winding will change between the first and second active segments. Accordingly, at least one of the conductive elements will be separated from the magnets of the rotor by a different distance or in a different orientation relative to the magnets in the second active segment compared to the first active segment.

For example, a plurality of conductive elements may be packaged in a bundle. The bundle can be twisted in the second inactive area. For example, the bundle can be twisted as it extends around a turn in the second inactive area. The placement of different conductive elements within a bundle can change when the bundle is twisted. As a result, at least one of the conductive elements in the bundle will be at a different separation distance from the magnets of the rotor in the second active segment compared to the first active segment. For example, a twisted bundle may include rotation of the bundle about its longitudinal axis. The shape of the bundle may be identical in cross section in the first and second active segments, but the placement of the conductive elements within the bundle may vary between the first and second active segments. The bundle can be twisted in each inactive area of the stator or only in some inactive areas. Subsequent twists may be the same, for example, a twist in the first inactive region may include a selected amount of rotation of the bundle about the longitudinal axis, and a subsequent twist in the second inactive region may be the same. Rotation may be included. Subsequent twists may include rotations to reverse previous changes, such that, for example, every second active segment (where the twist occurs) will have conductive elements disposed in the same configuration.

Rotation of the inactive region may include a change of direction relative to the phase winding (eg, change of direction of current flow). Each rotation can reverse direction to the phase winding so that the conductive element can extend across the active area and back from one inactive area to the other. Twisting of the inactive area may include changing the placement and/or orientation of individual conductive elements within the bundle/of the bundle as a whole. Torsion can occur during rotation.

The inactive segment of the serpentine structure of the slotless phase winding may be a first inactive segment, and the serpentine structure of the slotless phase winding may further include a second inactive segment and a third active segment. The second inactive segment can couple the second active segment to the third active segment. The second inactive segment may include a rotation provided to the first inactive area. At least one of the conductive elements may be twisted in the first inactive region, for example twisting may occur during rotation. The twist in the first inactive region may include a half twist (eg, rotation of the bundle of conductive elements by 180 degrees about a longitudinal axis of the bundle). The twist in the second inactive region may also include a half twist. Twisting can provide a change in the position of individual conductive elements within the bundle and/or a change in orientation of the conductive elements/bundles. For example, the torsion can be configured so that the internal arrangement of the conductive elements in the first active region differs from the internal arrangement in the second active region. A half twist may include a 180 degree rotation when comparing the first active segment to the second active segment. The conductive element and/or bundle may be twisted or compressed entirely in the inactive area.

A bundle of conductive elements may be at least 5 elements deep, such as 10 elements deep. In other words, the conductive elements forming the bundle may be arranged in layers with at least 5 (eg, 10 or more) layers of discrete conductive elements included. Bundles of elements may be mechanically connected and/or supported. For example, potting materials may be used to bind different conductive elements together. For example, the conductive elements may be molded together, for example the stator itself (including the conductive elements) may be molded with a polymer or resin to serve as a support structure. The bundle of conductive elements can be twisted through 360° in the inactive area. This can reduce the volume associated with the windings without changing the spatial arrangement of the conductive elements through twisting one inactive area.

The stator may be a multi-phase stator. The slotless phase winding may be a first slotless phase winding, and the stator is a multi-phase slotless stator including a plurality of slotless phase windings. Each of the plurality of slotless phase windings may be a phase winding of the type described above. A first active segment of the first slotless phase winding may be offset from a second active segment of the first slotless phase winding in an active region. Each of the plurality of slotless phase windings may be arranged in a serpentine structure. The meander of the first slotless phase winding may be interlaced with one or more meanders of the other slotless phase windings of the stator. For example, each of the phase windings may be arranged in a serpentine structure that repeats with respect to the stator. The repeating structure of each phase winding can be offset with respect to the structure of the other phase windings, so that the conductive elements of the different phase windings in the active area can all be provided on the stator without overlapping. The first active segment of the second slotless phase winding may be disposed between the first and second active segments of the first slotless phase winding. The inactive segment of the second slotless phase winding may be coupled to the first active segment of the second slotless phase winding. The inactive segment of the second slotless phase winding may include a turn provided in the second inactive region, and at least one of the conductive elements of the second slotless phase winding may be twisted in the second inactive region.

The stator may be arranged to allow a conductive element of the turns of the first slotless phase winding to pass through the turns of the second slotless phase winding. The second active segment of the first slotless phase winding may be disposed in an active area between the first and second active segments of the second slotless phase winding. A turn of the first slotless phase winding may be disposed adjacent to a turn of the second slotless phase winding. The first slotless phase winding may be provided with the same twist as the second slotless phase winding. For example, a change in the configuration/orientation of the conductive elements of the first phase winding between the first and second active segments is equivalent to a change in the configuration/orientation of the conductive elements in the second phase winding between the first and second active segments. can be the same The first active segment of the third slotless phase winding may be provided in an active region between the first and second active segments of the first slotless phase winding. Both the second and third phase windings may be identical to the first winding. Additional phase windings may also be provided.

Aspects of the present disclosure may provide an electrical machine comprising a stator as disclosed herein, and a rotor carrying a plurality of magnets. The electrical machine is arranged such that the magnets carried by the rotor are aligned with the active area of the stator. Electrical machines may include motors and/or generators as disclosed herein. The distance of the air gap between the magnets of the rotor and the active area of the stator may be smaller than the cross-sectional depth of the plurality of conductive elements of the slotless phase winding. For example, the depth of the bundle of conductive elements can be greater than the air gap. The depth of the conductive element may be greater than the air gap. For example, the conductive element may fill at least half of the magnetic gap, such as 60% or more of the magnetic gap. A flux ring may be provided after the phase windings (eg away from the rotor). The flux ring may be configured to close the magnetic field circle. The magnetic gap may include the distance of separation between the flux ring (eg, an inner surface thereof) and the permanent magnets of the rotor (eg, an outer surface thereof). The flux ring may have a depth similar to the magnetic air gap depth. For example, the flux ring depth may be substantially the same if not higher. For example, the air gap may be less than 1 mm, such as less than 0.6 mm.

Some examples of the present disclosure will now be described by way of example only with reference to the drawings.

1 shows a schematic diagram of an electric machine with a stator and a rotor.
2 shows a schematic diagram of stator windings.
3 shows a schematic diagram of stator windings.
4 shows a schematic diagram of stator windings.
5 shows a schematic diagram of stator windings.
6 shows a schematic diagram of stator windings.
7 shows a schematic diagram of stator windings.
8 shows a schematic diagram of stator windings.
9 shows a schematic diagram of stator windings.
10 shows a schematic diagram of stator windings.
11 shows a schematic diagram of stator windings.
12 shows a schematic diagram of stator windings.
13 shows a schematic diagram of stator windings.
14 shows a schematic diagram of a radial gap electric machine.
15 shows a schematic diagram of the steps of a method for manufacturing stator windings.
16 shows a schematic diagram of stator windings.
17 shows a schematic diagram of stator windings.
18 shows a schematic diagram of the steps of a method for manufacturing stator windings.
19 shows a schematic diagram of a cross-section of a subsequent active segment.
20 shows a schematic diagram of a cross-section of a subsequent active segment.
Like reference numbers in the drawings are used to indicate like elements.

Embodiments of the present disclosure relate to stators for electrical machines. In particular, the stator is provided with one or more phase windings. The phase windings are arranged with insulated conductors bent and twisted in the inactive area of the stator. The conductors may be straight and untwisted across the active area of the stator. The conductors will then be twisted and bent in the inactive area, thereby changing the placement and/or orientation of the conductors. The distribution of conductive elements will depend on the active area of the stator. This can lead to a more uniform distribution of the field within the stator and can also reduce cyclic voltage losses when operating the stator.

1 shows an electric machine 1 . The upper portion of FIG. 1 is a cross-sectional view of the electric machine (eg in a plane passing through the axis of rotation). The lower portion of FIG. 1 is a sectional view of the electric machine in plane A-B.

The electric machine includes a stator (10) and a rotor (2). An air gap 9 is provided between the rotor 2 and the stator.

The stator 10 includes a phase winding 7 and a flux ring 8 . The stator 10 has an active area and first and second inactive areas. An active segment 71 is shown in the active area. A first inactive segment 72 is shown in the first inactive area and a second inactive segment 73 is shown in the second inactive area.

The rotor 2 has a central shaft 21, a coupling member 22 and a plurality of permanent magnets 6.

The electric machine (1) comprises a housing (4) with a bearing assembly (3). The housing 4 includes a mounting plate 5 .

In the example of figure 1, the electric machine 1 is a radial gap machine. The electric machine 1 can be a motor, in which case the stator 10 can be used to drive the rotation of the rotor 2 and/or can be a generator, in which case the stator 10 can be a rotor 2 ) can be used to use the electrical energy generated by the rotation of

The stator 10 and the rotor 2 are housed in a housing 4 . Housing 4 and mounting plate 5 surround stator 10 and rotor 2 to accommodate these components. The electrical machine 1 is symmetrical about a central axis, which is the axis of rotation of the rotor 2 .

The rotor 2 is provided radially within the stator 10 (and housing 4). A central shaft 21 of the rotor 2 extends along a central axis (axis of rotation of the rotor 2). The central shaft (21) is coupled to the housing (4) via a bearing assembly (3). The bearing assembly 3 may include two bearing assemblies. A first bearing assembly 3 is provided at the first end of the central shaft 21 (where the shaft is surrounded by the housing 4). A second bearing assembly 3 is provided in a second area of the central shaft 21 remote from the first end (where the shaft passes through the mounting plate 5). Mounting plate 5 is coupled to the shaft radially outward from central shaft 21 (and stator 10). A coupling member 22 extends radially outward from the shaft to provide an outer cylindrical drum for the rotor 2 . A permanent magnet 6 is provided on the rotor drum.

The stator 10 is positioned radially outward from the rotor 2 . The air gap 9 serves as a radial gap between the permanent magnet 6 and the phase winding 7 . The rotor 2 is cylindrical (eg permanent magnets 6 are provided on a cylindrical surface). The stator 10 is cylindrical and hollow (eg, the phase windings 7 are provided on a cylindrical surface). The cylindrical surface of the magnet (6) and the phase winding (7) are separated by a hollow cylindrical air gap (9). Windings are provided on the mounting surface of the stator 10 . The mounting surfaces are located radially outward of the windings facing inward (towards the magnets 6 of the rotor 2). The stator windings (7) are surrounded by a flux ring (8). In other words, the flux ring 8 is arranged radially outward of the phase winding 7 . A flux ring (8) is provided in the active area of the stator (10). A housing 4 is provided radially outward of the flux ring 8 to accommodate all components within the flux ring.

When the rotor 2 is inserted into the stator 10, the permanent magnets 6 of the rotor 2 are aligned with the active area of the stator 10. The permanent magnets 6 are located radially inside the active area of the stator 10 . The active area of the stator 10 extends along the extent of the permanent magnet 6 in a direction parallel to the axis of rotation of the rotor 2 . Thus, there are permanent magnets 6 located radially within the active area of the stator 10 . The permanent magnets 6 are not located radially in the inactive area of the stator 10 . Thus, the magnetic field in the active area is much higher than in the non-active area of the stator 10. The inactive area is outside the longitudinal extent of the permanent magnet 6 . An inactive region is separated by an active region. In other words, the cylindrical surface of the stator 10 presents an active area, and areas on either side of the cylindrical surface (along the axial length) are inactive areas.

The phase winding 7 rotates in the inactive region so that it can return to the active region. In the first inactive area, the first inactive segment 72 extends radially outward as it rotates. The windings 7 of the first inactive region can extend radially farther from the axis of rotation of the rotor 2 than the windings 7 of the active region. The inner surface of the first inactive segment 72 may be positioned away from the axis of rotation by the same distance as the inner surface of the first active segment 71 . The outer surface of the first inactive segment 72 may be located farther from the axis of rotation than the outer surface of the first active segment 71 . The first inactive segment 72 can be curled radially outward as it is rotated 180 degrees to return to the active area.

In the second inactive area, the second inactive segment 73 extends radially inward as it rotates. The second inactive segment 73 may extend into the hollow region of the housing 4 of the rotor 2 toward the axis of rotation. The inner surface of the second inactive segment 73 can be located closer to the axis of rotation of the rotor 2 than the inner surface of the active segment 71 . The second inactive segment 73 can be curled radially inward as it rotates 180 degrees to return to the second active region. In the region of the active segment 71 and the second inactive segment 73 the housing 4 can be cylindrical. The housing 4 can be tapered radially outward in the region of the first inactive segment 72 . The first and second inactive segments can be radially fitted within the housing 4 in a region outside the longitudinal extent of the magnet 6 on the rotor 2 .

The rotor 2 is configured to rotate around a rotational axis. The bearing assembly 3 is configured to permit rotation of the rotor 2 relative to the stator 10 (and housing 4 , for example, about a rotational axis). Thus, the permanent magnets 6 of the rotor 2 can move (rotate) relative to the phase windings 7 of the stator 10 .

The active segments of the phase winding 7 are arranged to extend across the active area of the stator 10 . The active segment may extend in a straight direction running parallel to the axis of rotation of the rotor 2 . The inactive segments are arranged to join adjacent active segments such that each active segment 71 can extend linearly across the active area. Each adjacent active segment 71 will extend across the active area in opposite directions (eg, from a first inactive area to a second inactive area, then from the second inactive area to the first inactive area). An active segment may be provided through 360 degrees of the active area of the stator 10 . The inactive segments may be arranged such that straight active segments span the entire active area of the stator 10 .

In some or all of the inactive area, the inactive segment may be twisted. For example, the phase winding 7 may twist as it rotates in one or more inactive regions. The twisting of the phase winding 7 will now be described with reference to subsequent figures.

The upper portion of FIG. 2 shows an enlarged cross-sectional view of the phase windings of the stator 10 . The lower part of FIG. 2 shows a reduced view of a part of the electrical machine 1 from which an enlarged view has been taken.

In the example of Figure 2, the stator 10 has three-phase windings. As shown, there is a first phase winding marked 'I', a second phase winding marked 'II' and a third phase winding marked 'III'. The upper portion of FIG. 2 shows a cross section in the active area of the stator 10 . Two active segments are shown for each of the phase windings. Each phase segment has one active segment 71 to the left of the center line and one active segment 71 to the right of the center line. The active segments 71 of each phase winding on the right are indicated by 71-I, 71-II and 71-III, respectively. The phase windings are placed in sequence. The sequence is repeated with each subsequent active region (eg, I, II, III). In other words, the three-phase windings are interlaced with each other. The three-phase windings extend around the entire active area of the stator (10). When it extends circularly, it keeps a fixed phase offset from each other (eg, tracks the same shape as it extends around the active area). Reference numerals 61 and 62 indicate different pole directions for different active segments. As can be seen, between the first active segment 71 and the subsequent active segment 71 for each phase winding the pole direction has changed (eg as the current carrying element is now rotated 180 degrees).

In addition to rotating 180 degrees in the inactive region, the phase windings can also be twisted in the inactive region. An example of such a twist will now be described with reference to FIG. 3 .

3 shows a schematic diagram of a phase winding. In the central part of FIG. 3 , the diagram shows the shapes the phase windings may take when extended around the stator 10 . As will be appreciated, FIG. 3 shows a plan view, but in the case of a radially gapped stator the surface will be cylindrical. The phase winding includes a series of active segments (71) in the active area of the stator (10). Dotted lines across the figure show where the active area is. The area above and below the dotted line is the inactive area. A first inactive area is shown at the bottom of the figure with a first inactive segment 72 and a second inactive area with a second inactive segment 73 is shown at the top of the figure.

A phase winding consists of a plurality of conductive elements. Each conductive element includes a conductor (eg copper wire) surrounded by an electrically insulating housing. There may be a plurality of such conductive elements within the phase winding. The conductive elements may be disposed together as a bundle of conductive elements.

The active segments extend across the active area of the stator 10 from one inactive area to the other. The active segments extend across the active area in an alternating direction from one active segment 71 to the next active segment. Whenever an active segment extends across the active area, it extends in a straight line across the active area. In the case of a radially gapped stator 10, this active segment would extend across the active area parallel to the axis of rotation. The active segments are all parallel to each other. The bundle of conductive elements may take the same shape (in cross section) for each active segment 71 . However, the placement of conductive elements within the bundle may change as the bundle is twisted.

All inactive segments of the first inactive area are the same. This first inactive segment 72a has no twist in the first inactive region. As can be seen, when the bundle of conductive elements enters the first inactive area from the active area, the bundle rotates 180 degrees back toward the active area. As the bundle rotates, the conductive element that started outside the rotation remains outside the rotation and returns to the active area. Similarly, the conductive element inside the turn remains inside the turn. As can be seen in FIG. 3 , while entering the first inactive region, the leftmost conductive element as the rightmost conductive element exits the first inactive region and reenters the active region. Likewise, on entry, the rightmost element exits as the leftmost element.

In this sense, when looking at the cross section of the active segment 71 before and after passing through the first inactive region, the arrangement of the conductive elements within the bundle will be the same. That is, when viewing a cross section in a direction opposite to a direction in which the conductive element extends (eg, a direction opposite to the direction of current flow). When viewing cross-sections of adjacent active segments before and after rotating the first inactive region in the same plane (i.e. when viewing both cross-sections in the same direction), one active segment 71 is (at the separation distance of the two active segments) will be a mirror image of the other active segment (with respect to the plane perpendicular to it).

In the second inactive area, three different arrangements for the second inactive segment are shown. Among these are an untwisted second inactive segment 73.a, a half twisted second inactive segment 73.c and a quarter twisted second inactive segment 73.d.

The second untwisted inactive segment 73.a is the same as the untwisted segment shown in the first inactive area.

The half-twisted second inactive segment 73.c has a twist such that the placement of the conductive elements within the bundle changes as it moves through the second inactive area. In this example, the bundle of conductive elements is twisted such that the leftmost conductive element entering the second inactive area also exits the second inactive area as the leftmost conductive element. Similarly, the rightmost conductive element on entry is the rightmost conductive element on exit. Thus, when looking at an element when exiting and entering the same plane in the same direction, it will look the same. However, when viewed in the same plane but in the opposite direction to the current flow, it would be a mirror image of the centerline.

The quarter-twisted second inactive segment 73.d has a twist such that the placement of the conductive elements within the bundle changes as it moves through the second inactive region. In this example, a bundle of conductive elements is twisted so that the elements enter aligned in a plane parallel to the surface of the stator 10 and exit aligned in a plane perpendicular to the surface of the stator 10 . In other words, the element on exit has been rotated about 90 degrees relative to the element on entry.

As such, the active segments are straight and will not twist, and will move parallel to each other. However, the placement of the conductive elements within the active segment will vary. In particular, as the conductive element passes through the second inactive segment with a quarter twist, the placement of the conductive element within the bundle will change (eg relative to the magnet 6 on the rotor 2). As a result, for at least one of the conductive elements, that element will be closer to or farther from the magnet 6 on the rotor 2 in the adjacent active segments coupled together via the torsional inactive segment. The conductive elements may or may not be the same length in the inactive area.

In the example shown in FIG. 3 , the black rectangle shown in the cross section above and below the main diagram of the shape of the winding represents the first turn of the four-turn phase winding and the other white rectangles represent the other three turns. The position of the black first turn changes according to the type of bending and twisting of the inactive area. This may enable voltage integration along the entire active area of the stator 10 of all conductive elements of the phase windings to minimize cyclic voltage losses.

The upper portion of FIG. 4 shows a cross-sectional view of the stator 10 including phase windings (eg in a plane through the axis of rotation). The lower portion of FIG. 4 shows a cross-sectional view in plane C-D (the active area of the stator 10). In this example, the stator 10 is a three-phase, sixteen pole winding.

4 shows a stator 10 with three-phase windings. As can be seen, the stator windings are straight in the active region, but not straight in the first and second inactive regions. As in the stator 10 described above, the first inactive segment includes a turn extending radially outward from the first inactive area. The second inactive segment includes a rotation extending radially inwardly in the second inactive area. Three-phase windings run in parallel in the active region. The three-phase windings are not parallel in the non-active region. Instead, the phase windings are formed in a staggered formation so that each phase winding passes through the other phase windings in the inactive region to maintain the configuration of the phase windings in the active region (e.g., I, II, II, III). ) is placed. For example, each inactive segment may extend radially inward or outward to provide a three-dimensional rotation. Each inactive segment can pass within a three-dimensional bend of one or more other inactive segments.

The upper part of FIG. 5 shows an enlarged view of the phase windings of the stator 10 and the lower part of FIG. 5 shows a further enlarged view of the phase windings of the stator 10 . A cross section is taken in the active area of the stator (10). In the example of FIG. 5 , the stator 10 also includes one or more winding support structures. The winding support structure is configured to mechanically support the conductive element of each phase winding. The support structure may be configured to hold the bundle of conductive elements together (eg, in a parallel configuration). The support structure may include a bundle support structure 76 . A bundle support structure 76 is disposed surrounding each phase winding to hold the phase winding in a selected cross-sectional shape. The bundle support structure 76 may hold the individual phase winding active segments in a parallel arrangement with each other.

The upper portion of FIG. 6 shows a schematic diagram to illustrate an exemplary modification of the phase windings of the stator 10 . The lower part of FIG. 6 shows an enlarged view of one region of the upper part of FIG. 6 . The cross section in FIG. 6 is in the active area of the stator 10 .

6 shows a stator 10 with three-phase windings. Four active segments (SX, S1, S2 and S3) are shown. Each of the 3-phase windings has 4 turns (eg conductive elements) per phase. Each of these rotations is denoted as 'a', 'b', 'c' and 'd' to indicate how the placement changes between adjacent segments (due to twisting of the inactive area). To illustrate this, the first turn d for the first phase winding is shown as a black rectangle. As can be seen, between sectors S1 and S2 and between sections S2 and S3, the placement of the phase windings is changed. Active segments 71.x-I, 71.x-II, and 71.x-III are shown to illustrate how placement changes between adjacent active segments.

The upper portion of FIG. 7 shows a schematic diagram to illustrate an exemplary modification of the phase windings of the stator 10 . The lower portion of FIG. 7 also illustrates an exemplary alteration of the phase windings of the stator 10 , but shows a schematic diagram to illustrate an exemplary alteration of subsequent regions of the stator 10 . The cross section in FIG. 7 is in the active area of the stator 10 . In other words, two adjacent active segments Sn and Sn+1 are shown. Each of the three-phase windings has four turns a, b, c, d (e.g., a conductive element or group of conductive elements). Four turns can give a bundle. As can be seen, the placement within an active segment for a phase winding changes between adjacent segments. The three-phase windings remain in order (I, II, III, I, II, III), but the internal arrangement of at least one of the phase windings changes between adjacent active segments. For example, the internal arrangement of each winding changes from a, b, c, d to d, c, b, a.

The upper portion of FIG. 8 shows a cross-sectional view of the stator 10 including the phase windings (eg in a plane through the axis of rotation). The lower portion of FIG. 8 shows a cross-sectional view in plane C-D (the active area of the stator 10). One phase winding is shown although more may be provided. The winding may have a support structure in the inactive area (shown by the black fill). The inner side of the active area may have a winding support structure 76 . Winding support structure 76 may include a coating such as a polymer coating. The winding support structure 76 may be configured to support and hold the phase windings in place on the mounting surface of the stator 10 .

9 to 11 show schematic diagrams of exemplary arrangements of phase windings relative to stator 10 .

9 shows a region of a stator 10 with three-phase windings. In other words, the view is flat, but in the case of a radial gap it is on a cylindrical surface. As shown, the three-phase windings are interlaced with each other in a repeating pattern. The active segments are adjacent to each other and parallel. The inactive segments are arranged to maintain the interlaced pattern of the three-phase windings. For example, in the inactive area, the phase winding can be bent in a three-dimensional pattern so that the phase winding can pass through gaps in adjacent phase windings in the inactive area. 10 shows such an exemplary arrangement in which inactive segments extend radially in/outward so that adjacent segments can pass through each other to return to the active area. There may be different bending patterns for different inactive segments. The repeating pattern of active segments I, II and III is maintained, and the rotation of the inactive segments is arranged so that this pattern can be maintained with the individual inactive segments passing each other in the inactive area. Three-dimensional bending in the inactive region may allow the longitudinal extent of the phase winding to be reduced (eg to occupy less volume inside the housing 4 ). This not only improves the thermal conductivity but also reduces the size. 11 shows a stator 10 with different types of torsion in the inactive region. For example, as the rotation of the inactive area moves radially in/out, there may be a twist in this area as well (this twist may be different). For example, quarter and/or half twists may be provided. Also, adjacent segments may have different twists in the same inactive area.

12 and 13 show schematic diagrams of the arrangement of the phase windings relative to the stator 10 .

The above examples relate to radial gap electrical machines. The present disclosure may also be extended to axial gap electrical machines. In this case, the stator 10 and the rotor 2 are not cylindrically separated from each other, but instead both the stator 10 and the rotor 2 may be cylinders offset in the axial direction. The phase windings will instead be provided on the circular surface of the cylinder (rather than the cylindrical surface). As a result, the phase windings extend radially inward and outward on a flat circular surface (rather than a cylindrical surface running parallel to the axis of rotation).

12 and 13 show this arrangement. The active area of stator 10 is an annular area. The radially inner area of the annular shape is the first inactive area, and the radially outer area of the annular shape is the second inactive area. A phase winding extends across the active area between the first and second inactive areas. As shown, the phase windings and segments are more closely packed in the inner region than the outer region. Adjacent active segments are not parallel, but all intersect at the center of the circle if they continue in a straight line away from each other. 12 and 13 also show the terminal ends X and Y for each of the three-phase windings. The distal end is for coupling the phase winding to a power source (for the motor) or a means for obtaining the generated power (for the generator). FIG. 13 shows a similar arrangement to FIG. 12 but with a three-dimensional rotation on the inactive area so that the inactive segments can pass through each other when returning to the active area.

14 shows the electrical machine 1 . The top of FIG. 14 is a sectional view of the electrical machine 1 (eg in a plane through the axis of rotation). The lower part of Fig. 14 is a sectional view in plane A-B. The electrical machine 1 is shown except that the rotor 2 is shown with spoke couplings 24 for coupling the central shaft 21 to the rotor drum 23 provided with the permanent magnets 6. similar to that of 1. One or more holes may be provided in the housing 4 to pass terminal wires of the stator 10 out through the housing 4 .

Figure 15 shows the steps of a method for manufacturing a phase winding.

15 illustrates intermediate steps in an exemplary fabrication method for fabricating the phase windings of the present disclosure. The phase winding includes a plurality of active segments (181) and inactive segments (182, 183). Also shown are terminal conductors 184 for connecting the stator windings to external components such as power sources (for motors) or power drains (for generators). The active segment 181 of the phase winding is formed from straight and parallel conducting elements. For this purpose, for example, clamping and/or potting tools covering only the active area segments 181 can be used, or additional fabrication of the conductive element can be achieved using fixing means such as baking enamel, polymers or UV curable resins, or the like. A securing material may be provided to provide a parallel arrangement of the conductive elements. The cross-sectional shape and/or curvature of the inactive area may be different. The inactive area can then be bent to give the serpentine arrangement of the active area as shown in the previous figures. Conductive elements can be molded and/or fused together in the active area (eg, to provide a bundle).

16 shows each active segment 181 in two configurations: an 'up' configuration (shown at 181u) and a 'down' configuration (shown at 181d). It shows a schematic diagram of a phase winding arranged as one of the As shown, the inactive segments include (i) a twisted inactive segment 185 in which the conductive element bends back toward the active area with twist, and (ii) an untwisted inactive segment in which the conductive element bends back toward the active area without twisting. It is divided among the non-active segments 187. As shown, the two twisted inactive segments 185 are evenly distributed (eg, in opposite directions). Thus, on one half the active segments are in up configuration and on the other half are in down configuration.

FIG. 17 shows an arrangement similar to FIG. 16 except that there is only one twisted inactive segment 185 in the winding of FIG. 17 . Twisted inactive segment 185 is on the opposite side of the phase winding to terminal conductor 184. Half of the active segments are in the up configuration and half are in the down configuration. An inactive twisted through 360° such that the conductive element (or bundle of conductive elements) is in the same configuration in an adjacent active segment, even though some or all of the untwisted inactive segments are twisted in the inactive segment separating the two active segments. segment can be replaced. This arrangement can reduce the volume requirements for the phase windings.

18 shows a schematic diagram of the steps of a method for manufacturing stator windings. In particular, FIG. 18 illustrates potential intermediate steps in the process of fabricating phase windings with more than one turn per phase. 18 shows an active area 171 as well as a first inactive area 172 and a second inactive area 173 . The phase windings include two inactive segments 185 twisted but not 360° twisted (eg, inactive segments provided with partial twist). The remaining inactive segment is an inactive segment 186 with a 360° twist (which of course could instead be provided by a rotating inactive segment through 720° or 360° multiples or more and/or a non-twisting inactive segment). The number of active segments in each configuration is the same (e.g., the partial twist is distributed around the winding, so that the number of active segments in one configuration is equal to the 'up' and 'down' distribution in FIGS. 16 and 17 ). to balance the number of opposite configurations).

19 shows a subsequent series of cross sections through four active segments 181 . The phase winding includes a plurality of conductive elements 191 arranged in a bundle. In this example, the bundles are laid out in a rectangular shape, but other options may be used. 160 conductive elements 191 are shown over four turns T1, T2, T3 and T4. To illustrate the different variations of arrangement, a first layer FL and a last layer LL are shown.

As can be seen, no twist is provided between 'a' and 'b' while the bundle rotates in the inactive segment. Thus, the order is reversed (T1 to T4, T4 to T1), and the first and last layers remain intact. This is a twist-free rotation (187). Between 'b' and 'c' a 180° twist is provided while the bundle rotates in the inactive segment. As such, the order and layers are reversed. That is, the four rotations changed their order again, and the first and last layers were switched. This is a 180° torsional rotation (185). Between 'c' and 'd', a corresponding change occurs between 'a' and 'b', and only the layers remain (so that the first and last layers are different compared to the first twist-free turns 187) .

20 shows an arrangement similar to that of FIG. 19 . 20 shows three layers T1, T2 and T3. A 180° twist is provided while the inactive segment rotates between 'a' and 'b'. As such, the order of rotation is reversed as is the order of the layers. Since no twist is provided between 'b' and 'c', the order of turns changes, but the order of layers remains the same. A 360° twist is provided between 'c' and 'd'. As can be seen, the rotation changes the order again, but the order of the layers remains the same. This is a 360° twist (186). Referring to the darkest rectangle (including the filled circles), you can see how the position of the conductive element changes within the bundle. These changes are controlled to minimize voltage integrals associated with the phase windings.

It will be understood from the foregoing that the examples shown in the drawings are illustrative only and include features that may be generalized, eliminated or substituted as described herein and set forth in the claims. Referring generally to the drawings, it will be understood that schematic functional block diagrams are used to represent the functions of the systems and devices described herein.

As will be appreciated by the skilled reader in the context of this disclosure, each example described herein can be implemented in a variety of different ways. Any feature of any aspect of this disclosure may be combined with any other aspect of this disclosure. For example, a method aspect may be combined with an apparatus aspect, and features described with reference to the operation of a particular element of an apparatus may be provided in a method that does not use this particular type of apparatus. Further, each feature of each example is intended to be separable from a feature described together unless explicitly stated that some other feature is essential to its operation. Each of these separable features may, of course, be combined with any of the other features of the example it is described, or a combination of features of any other example or any of the other features described herein. Also, equivalents and modifications not described above may also be used without departing from the invention. Other examples and variations of this disclosure will be apparent to those skilled in the art in the context of this disclosure.

Claims (25)

A stator interacting with a magnet carried by a rotor of an electrical machine comprising:
an active area disposed in alignment with the magnet carried by the rotor;
a first inactive region and a second inactive region separated by the active region; and
A slotless phase winding comprising a plurality of conductive elements, each conductive element including a conductor provided in an insulating housing, the slotless phase winding is arranged in a serpentine structure, the structure comprising:
a first active segment wherein the conductive element extends across the active area from the first inactive area to the second inactive area;
a second active segment wherein the conductive element extends across the active area from the second inactive area to the first inactive area; and
an inactive segment coupling the first active segment to the second active segment, the inactive segment including a rotation provided to the second inactive region, and wherein at least one of the conductive elements twists in the second inactive region. stator interacting with magnets. According to claim 1,
wherein the plurality of conductive elements are substantially parallel to each other in the first and/or second active segments. According to claim 1 or 2,
wherein the conductive element of the first active segment is substantially parallel to the conductive element of the second active segment. According to any one of claims 1 to 3,
wherein the conductive element extends straight across the active area without twisting. According to any one of claims 1 to 4,
wherein the slotless phase winding is a first slotless phase winding, and wherein the stator is a multi-phase slotless stator comprising a plurality of slotless phase windings. According to claim 5,
wherein the first active segment of the first slotless phase winding is offset from the second active segment of the first slotless phase winding in the active area. According to claim 6,
wherein each of the plurality of slotless phase windings is disposed in a serpentine structure. According to claim 7,
wherein the serpentine structure of the first slotless phase winding is interlaced with the serpentine structure of one or more of the other slotless phase windings of the stator. According to claim 8,
wherein the first active segment of the second slotless phase winding is disposed between the first and second active segments of the first slotless phase winding. According to claim 9,
the inactive segment of the second slotless phase winding is coupled to the first active segment of the second slotless phase winding;
wherein the inactive segment of the second slotless phase winding comprises a turn provided in the second inactive region, and wherein at least one of the conductive elements of the second slotless phase winding is twisted in the second inactive region. Stator interacting with. According to claim 10,
wherein the stator is arranged to allow the conducting element of a turn of the first slotless phase winding to pass through a turn of the second slotless phase winding. According to claim 11,
wherein the second active segment of the first slotless phase winding is disposed in an active area between the first and second active segments of the second slotless phase winding. According to any one of claims 10 to 12,
wherein rotations of the first slotless phase winding are disposed adjacent to rotations of the second slotless phase winding. According to any one of claims 10 to 13,
wherein the first slotless phase winding is provided with the same twist as the second slotless phase winding. According to any one of claims 5 to 14,
wherein a first active segment of a third slotless phase winding is provided in an active area between the first and second active segments of the first slotless phase winding. According to any one of claims 1 to 15,
the inactive segment of the serpentine structure of the slotless phase winding is a first inactive segment, and the serpentine structure of the slotless phase winding further includes a second inactive segment and a third active segment;
wherein said second inactive segment couples said second active segment to said third active segment, said second inactive segment comprising a rotation provided to said first inactive region. 17. The method of claim 16,
wherein at least one of the conductive elements is twisted in the first inactive region. 18. The method of claim 17,
wherein the twist in the first inactive region comprises a half twist and the twist in the second inactive region also comprises a half twist. According to any one of claims 1 to 18,
The stator interacting with magnets, wherein the conductive filaments of the slotless phase winding are packaged into fiber bundles, the fiber bundles having a cross-sectional shape of orthogonal or hexagonal. According to any one of claims 1 to 19,
A stator interacting with a magnet, in which the conductor of each conductive element is of rectangular, circular or hexagonal cross-section shape. 21. The method of any one of claims 1 to 20,
the stator is positioned to provide a radial air gap between the stator and the rotor;
wherein the active segments of the slotless phase winding extend axially parallel to the axis of rotation of the rotor. 21. The method of any one of claims 1 to 20,
the stator is positioned to provide an axial air gap between the stator and the rotor;
wherein the active segments of the slotless phase winding extend in a radial direction orthogonal to the axis of rotation of the rotor. 23. The method of any one of claims 1 to 22,
the stator is for interacting with a magnet carried by a rotor of the electric motor, the stator is configured to apply current to the slotless phase winding to drive rotation of the rotor of the electric motor;
The stator is for interacting with a magnet carried by the rotor of the generator, the stator being responsive to rotation of the magnet of the rotor of the generator to harness energy from the generated current generated in the slotless phase winding. The stator interacts with the magnets, which are constructed. In the electric machine,
The stator according to any one of claims 1 to 23; and
a rotor carrying a plurality of magnets;
wherein the electrical machine is arranged such that a magnet carried by the rotor is aligned with an active area of the stator. 25. The method of claim 24,
and a distance of an air gap between a magnet of the rotor and an active area of the stator is less than a cross-sectional depth of the plurality of conductive elements of the slotless phase winding.

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